Lexmark Optra 4049 Series Service Manual Download Page 140

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6-2

4049-XXX

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Gear no. 6 and its stud on the motor bracket

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Gear no. 6 and its thrust washer

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Gear no. 7 and its stud on the rail

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Gear no. 7 and its thrust washer

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Gear no. 8 and its stud on the rail

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Gear no. 8 and its thrust washer

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Gear no. 9 and its stud on the rail

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The metering roller shaft and its bushings on the rail assembly

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The main metering backup roller and its stud and thrust washer

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The D-roller shaft and its bushings on the rail assembly

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The auxiliary metering roller and its stud on the rail, including
the snap-in groove and the snap ridges in the roller hole

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Gear no. 14 and its stud on the rail

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Gear no. 13 and its stud on the rail

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The auxiliary paper feed idler and its stud on the rail

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The prealigner drive idler and its stud on the rail

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The prealigner drive roller and its stud on the rail

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The prealigner backup roller and its shaft and thrust washer

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The fixed-center idler gear in the 500 sheet base and its shaft

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The idler gear in the 500 sheet base and its shaft

Use IBM no. 23 grease (Approved equivalent Shell Darina 1) to lubri-
cate:

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Front pivot latch studs

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Gear no. 8 teeth at gear no. 7 contact points

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Gear no. 9 teeth at gear no. 11 contact points

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Gear no. 9 teeth at gear no. 8 and gear no. 10 contact points

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Cover Hinge Spring tips

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Cartridge “ramps” at top center of both sides frames

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Latch handle tips

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Area of contact between fuser release bail and roll

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All release arms areas of contact of fuser solenoid lever.

Use grease, p/n 1329301 to lubricate gear nos. 2,3,4,5,6, and 12.
Use all the grease in the packet. Apply part of the grease, rotate the
gears, and apply the rest. The teeth of gears 3, 4, and 5 should be
completely coated.

Summary of Contents for Optra 4049 Series

Page 1: ...XXX OptraTM Series Lexmark is a trademark of Lexmark International Inc registered in the United States and or other countries Table of Contents Index Safety and Notices Trademarks Start Diagnostics Main Menu ...

Page 2: ...in this publication may be made at any time Publications are not stocked at the address given below requests for publications should be made to your point of purchase Comments may be addressed to Lexmark International Inc D22A 035 3 740 New Circle Road NW Lexington Kentucky 40550 U S A Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurr...

Page 3: ...re Laser xii Laserinformatie xii Lasermeddelelse xiii Huomautus laserlaitteesta xiii Laser notis xiv Laser melding xiv Avís sobre el Làser xv Japanese Laser Notice xv Chinese Laser Notice xvi Korean Laser Notice xvi Trademarks xvii Safety Information xviii Preface xxiii General Information 1 1 Power Consumption 1 2 Options 1 2 Maintenance Approach 1 3 Tools Required For Service 1 3 Abbreviations 1...

Page 4: ...Tests 2 22 Output Bin Sensor 2 22 Operator Panel Problem 2 22 Paper Feed Problem 500 Sheet Option or 200 Sheet Second Drawer Non Rt 2 23 Paper Feed Base Printer 2 23 Paper Feed Duplex Unit 2 25 Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder 2 26 Paper Feed Problem 200 Sheet Second Drawer Rt 2 26 Paper Feed Problem Dual Rear Feeder 2 27 Machine Level Information 2 27 Paper Feed Probl...

Page 5: ... 7 Envelope Print Test 3 7 Error Log 3 8 Flash Test 3 8 Fuser Temperature And Warm Up Time 3 8 Fuser Temperature 3 9 Fuser Warm Up Time 3 9 LCD Test 3 9 Maintenance Kit Count 3 10 Memory Tests 3 10 Page Count 3 10 Paper Feed Tests 3 10 Parallel Confidence 3 11 Permanent Page Count 3 11 Print Contrast 3 11 Print Registration 3 12 Print Test 1 3 13 Print Test 2 3 13 Print Test 3 3 14 Quick Disk Test...

Page 6: ...ser Solenoid Adjustment 4 7 Paper Feed Magnet Adjustment 4 8 Printhead Skew Adjustment 4 9 Removal Procedures 4 10 Covers 4 10 Right Cover Removal 4 10 Front Cover Removal 4 10 Left Cover Removal 4 12 Top Cover Removal 4 12 14 in 200 Sheet Paper Tray Top Cover 4 14 14 in 500 Sheet Paper Tray Top Cover 4 14 D roll Assembly Removal 4 14 Drive Motor Removal 4 14 Engine Board Removal 4 15 Exit Sensor ...

Page 7: ... 4 40 Duplex Option Bottom Cover And Entry Sensor Card Removal 4 41 Duplex Option System Card And Motor Removal 4 42 Dual Rear Feeder Edge Guide Asm 4 43 Dual Rear Feeder Gear Plate Asm 4 43 Dual Rear Feeder Right Cover 4 43 200 Sheet Second Drawer Rt 4 44 High Capacity Feeder Paper Feed Rollers 4 45 High Capacity Feeder Cover 4 47 Connector Locations 5 1 Major Assembly Locations 5 1 Gear Train 5 ...

Page 8: ...2 Lower Frame 7 4 Upper Frame 7 6 Printhead 7 8 Paper Feed 7 10 Paper Feed Alignment Gears 7 14 Paper Feed Drive 7 16 Standard Paper Tray 200 Sheet 7 18 Paper Tray 500 Sheet 7 20 Base for Paper Drawer 500 Sheet 7 22 Second Paper Drawer 200 Sheet 7 24 Optional Paper Drawer 500 Sheet 7 26 Fuser 7 28 Electronics 7 32 Transfer Roll 7 36 Duplex Option 7 38 Envelope and 100 Sheet Auxiliary Feeder 7 40 D...

Page 9: ... with other products programs or services except those expressly designated by the manufacturer are the user s responsibility Laser Notice The printer is certified in the U S to conform to the requirements of DHHS 21 CFR Subchapter J for Class I 1 laser products and else where is certified as a Class I laser product conforming to the requirements of IEC 825 Class I laser products are not considere...

Page 10: ...utzer oder bei ordnungsgemäßer Wartung durch den Kundendienst Laserbestrahlung die die Klasse I übersteigen würde Menschen keinesfalls erreicht Avis relatif à l utilisation de laser Pour les Etats Unis cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I 1 Pour les autres pays cette imprimante répond aux normes IEC 825 relatives aux ...

Page 11: ...lle di assistenza tecnica non ricevano radiazioni laser superiori al livello della classe 1 Avisos sobre el láser Se certifica que en los EE UU esta impresora cumple los requisitos para los productos láser de Clase I 1 establecidos en el subcapítulo J de la norma CFR 21 del DHHS Departamento de Sanidad y Servicios y en los demás países reúne todas las condiciones expuestas en la norma IEC 825 para...

Page 12: ... qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal a manutenção feita pelo utilizador ou condições de assistência prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J voor andere landen in IEC 825 ...

Page 13: ...kirjoitin on Yhdysvalloissa luokan I 1 laserlaitteiden DHHS 21 CFR Subchapter J määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 825 määrityksen mukainen Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle Kirjoittimessa on sisäinen luokan IIIb 3b 5 milliwatin galliumarsenidilaser joka toimii aaltoalueella 770 795 nanometriä Laserjärjestelmä ja kirjoitin on suunniteltu s...

Page 14: ...utsätts för laserstrålning över Klass I nivå vid normal användning underhåll som utförs av användaren eller annan föreskriven serviceåtgärd Laser melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR underkapittel J for klasse I 1 laserprodukter og er i andre land godkjent som et Klasse I laserprodukt i samsvar med kravene i IEC 825 Klasse I laserprodukter er ikke å betrakte som farlige ...

Page 15: ...25 Els productes làser de classe I no es consideren perillosos Aquesta impressora conté un làser de classe IIIb 3b d arseniür de gal li nominalment de 5 mil liwats i funciona a la regió de longitud d ona de 770 795 nanòmetres El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d un nivell de classe I durant una operació normal dura...

Page 16: ...xvi Service Manual 4049 XXX Chinese Laser Notice Korean Laser Notice ...

Page 17: ...CL 5 is Hewlett Packard Company s designation of a set of printer commands language and functions included in its printer products This printer is designed and manufactured by Lexmark International Inc to be compatible with the PCL 5 language This means the printer recognizes PCL 5 commands used in various applications programs and that the printer emulates the functions corresponding to the comma...

Page 18: ...ervicing of this product Professional service personnel should understand this and take necessary precautions Consignes de Sécurité Ce produit a été conçu testé et approuvé pour respecter les normes strictes de sécurité globale lors de l utilisation de composants Lexmark spécifiques Les caractéristiques de sécurité de certains éléments ne sont pas toujours évidentes Lexmark ne peut être tenu respo...

Page 19: ...ato Il personale di assistenza autorizzato deve quindi adottare le precauzioni necessarie Sicherheitshinweise Dieses Produkt und die zugehörigen Komponenten wurden entworfen und getestet um beim Einsatz die weltweit gültigen Sicherheitsanforderungen zu erfüllen Die sicherheitsrelevanten Funktionen der Bauteile und Optionen sind nicht immer offensichtlich Sofern Teile eingesetzt werden die nicht vo...

Page 20: ...ción de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias Informações de Segurança Este produto foi concebido testado e aprovado para satisfazer os padrões globais de segurança na utilização de componentes específicos da Lexmark As funções de segurança de alguns dos componentes podem não ser sempre óbvias A Lexmark não é responsável pela uti...

Page 21: ...guretat d algunes peces pot ser que no sempre siguin òbvies Lexmark no es responsabilitza de l us d altres peces de recanvi La informació pel manteniment d aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal profes...

Page 22: ...xxii Service Manual 4049 XXX ...

Page 23: ...ng field replaceable units FRUs Diagnostic Aids contains tests and checks used to locate or repeat symptoms of printer problems Repair Information provides instructions for making printer adjustments and removing and installing FRUs Connector Locations uses illustrations to identify the major components and test points on the printer Preventive Maintenance contains safety inspection guidelines lub...

Page 24: ...From a service standpoint models Lxi and Lxn are the same as Lx model Lxi is the same as Lx and model Rn is the same as R Models Lxi Lxn Lxi and Rn are not mentioned elsewhere in this manual The plus models have a different ROM SIMM RIP board and top cover and all have a maximum speed of 16 ppm There are no other hardware differences Processing speed and efficiency have been improved and scheduled...

Page 25: ...2MB and 4MB Integrated network options Token Ring Ethernet AppleTalk SCS IPDS 200 and 500 sheet paper trays of A5 letter and legal size 500 sheet second drawer with letter size paper tray Envelope feeder 100 sheet auxiliary feeder Duplex option Font cards bitmapped or scalable fonts 100MB Hard Disk Dual Rear Feeder Stat Alert Light High Capacity Feeder 1500 sheets R L Rt R Rt Rx Lx Lx Power Saver ...

Page 26: ... 2 1 This printer can be serviced without being connected to a host com puter After you complete the repair perform tests as needed to verify the repair Tools Required For Service Flat blade screwdriver 1 Phillips screwdriver 2 Phillips screwdriver 5 5 mm nut driver 8 mm wrench Needlenose pliers Diagonal pliers Spring hook Feeler gauges Analog or digital multimeter Parallel wrap plug 1319128 Seria...

Page 27: ...Area Network LASER Light Amplification by Stimulated Emission of Radiation LCD Liquid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply NVRAM Nonvolatile Random Access Memory OEM Original Equipment Manufacturer PICS Problem Isolation Charts PIXEL Picture Element POR Power On Reset POST Power On Self Test PQET Print Quality Enhancement Technology RIP Raster Image Processor ROS ...

Page 28: ... personal safety and to prevent damage to the printer Two digit codes are messages for the user but if they recur fre quently or at inappropriate times they may be symptomatic of a ser vice problem Use the service error code symptom table service checks and diagnostic aids to determine the corrective action necessary to repair a malfunctioning printer ...

Page 29: ...nsor in time See Duplex on page 2 16 24 Short Paper The defined paper size is too short to print data as formatted 25 Incorrect Manual Feed Input sensor made at wrong time May be due to the paper feeding manually while motors running and previous page in path 26 Duplex Tray Missing Duplex unit is installed but paper tray is not sensed 27 Change Envelope Paper Envelopes paper loaded are wrong size ...

Page 30: ...int the Print Menus test page Make sure the memory shown on the printout matches the installed memory 39 Complex Page Page too complex to print To verify that the printer recognizes all the installed memory go to the user menus and print the Print Menus test page Make sure the memory shown on the printout matches the installed memory 43 Font Card Not Supported Font card format not supported by pri...

Page 31: ... connected and printer top cover is closed 59 Duplex Cover Open Top cover of duplex unit is sensed open 62 Disk Full Not enough disk space for data that has been requested to be written to disk 63 Unformatted Disk Format the disk 64 Defective Disk The printer will ignore a disk it senses as defective Run the Quick Disk Test If the test fails the disk is defective or the data on track 1 is bad If t...

Page 32: ...r Roll Error Cannot start servo operation Verify correct cable connections from the engine board to the HVPS Make sure there is continuity between the transfer roller and its contact on the HVPS replace the transfer roll if the continuity is correct If there is no continuity make sure the HVPS con tact returns to its upward limit when depressed and make sure the left bearing of the transfer roll i...

Page 33: ...r 924 Error on page 2 20 927 Fan Stalled See Fan 927 Error on page 2 18 928 Erase Lamps Erase lamp assembly missing or dis connected 931 Printhead Error No first hsync See Printhead on page 2 30 932 Printhead Error Lost hsync See Printhead on page 2 30 934 Printhead Error Lost lock condition See Printhead on page 2 30 935 Printhead Error Mirror motor unable to reach operat ing speed See Printhead ...

Page 34: ...ngine Board Printhead crystal not functioning cor rectly Replace the engine board 960 Memory Error Bad or missing DRAM in the base DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the printer If the test fails or the problem recurs replace the DRAM SIMM 961 Memory Error Bad DRAM in the optional DRAM slot Reseat the DRAM and run the diagnostic Memory Test for DRAM POR the p...

Page 35: ...the network card is installed and grounded correctly If this error returns after a POR there is a soft ware or microcode incompatibility problem Do not replace the card Contact your next level of support 976 Network Card 2 Network card 2 software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a soft ware or microcode incompatibilit...

Page 36: ...port 979 Network Card 2 General network 2 card software error Verify that the network card is installed and grounded correctly If this error returns after a POR there is a software or microcode incompat ibility problem Do Not replace the card Contact your next level of sup port 990 Duplex Option Duplex error See Duplex on page 2 16 991 Duplex System Card Fail ure Duplex system board failure Replac...

Page 37: ...user warms to operating temperature Printer idle time is shorter if the fuser is already warm Note If the duplex unit is installed the duplex drive motor turns on for about five seconds just before the Ready screen appears 4 The ready screen appears on the display Note Diagnostics menu appears if you are in diagnostic mode 5 The drive motor and the mirror motor start The fan starts to run at high ...

Page 38: ...wer Non Rt on page 2 23 or Paper Feed Problem 200 Sheet Second Drawer Rt on page 2 26 Paper Feed Problem Enve lope Feeder 100 Sheet Auxil iary Feeder Paper Feed Problem Envelope Feeder 100 Sheet Auxiliary Feeder on page 2 26 Paper Feed Problem Dual Rear Feeder Paper Feed Problem Dual Rear Feeder on page 2 27 Paper Feed Problem 200 Sheet Second Tray Rt Paper Feed Problem 200 Sheet Second Drawer Rt ...

Page 39: ...ll amounts of toner deposited on them Clean the erase lamps and the printhead window Verify that all the erase lamps are working by powering on or off with the top cover open Verify that there is 24VDC on engine board Regularly Spaced Marks Regularly Spaced Marks on page 2 32 Skew all edges Skew all edges on page 2 33 Skew top and bottom only Skew top and bottom only on page 2 33 Light Print Light...

Page 40: ...ow ing voltages then stop the test and check the voltages again If any voltages are not correct replace the engine board If no problem is found enter the diagnostics mode and change the Charge Roll setting Users who run large jobs with very dense graphics in high humidity environments may get some print quality improvement from increas ing the Transfer setting users with more normal jobs will see ...

Page 41: ...lace the HVPS Blank Page Inspect the printhead shutter for proper operation and make sure the actuator on top of the cartridge is present and extends into the print head shroud when the printer top cover is closed A failed printhead will cause a 931 Service error rather than blank output Check the continuity of the HVPS cable The HVPS and transfer roll contacts should be clean and spring back when...

Page 42: ...he point where the feeder s friction rollers release the paper Dead Machine Possible causes no voltage reaching the printer LVPS failure blown LVPS fuse failure of the On Off switch or switch linkage or a shorted electrical component Check for the indicated voltages at the LVPS connection to the engine board If no voltages are present remove the LVPS cover and check fuse F1 and the power switch be...

Page 43: ...thus the printer engine board duplex unit sys tem board and the cables between them are all good If the duplex unit does not home immediately but homes after 5 or 6 seconds the duplex unit is receiving 34 VDC from the printer but is not communicating with the printer The duplex unit homes on its own as a signal that it is functional If the duplex unit does not home at all it is either damaged or i...

Page 44: ...ace at its front and rear and that the gear block assembly is correctly snapped into the bottom cover Run duplex diagnostics tests 1 and 2 to make sure there is no slippage in the paper path Make sure the flags of the duplex unit input and exit sensors move freely While the 23 is displayed press and hold the Return button while pressing the second button from the top and note the 7th and 8th digit...

Page 45: ... voltage at engine board J2 7 should be approximately 24 VDC when the top cover is up Short J2 7 to ground J2 6 to test the fan if the fan does not run check the continuity of the fan cable before replacing the fan A bad fan can pull down the 24 V line even if it runs check that J2 8 has between 21 and 26 VDC when the fan is running If the voltage is under 21 VDC replace the fan if the voltage is ...

Page 46: ...d 5 VDC when the lamp is to be off The lamp can be tested by briefly connecting this pin to ground Fuser 920 921 or 922 Error A 922 error during a POR caused by low line voltage can usually be cleared by doing another POR If the fuser lamp is lighting very dimly check for a 220 V lamp installed in a 110 V machine Check all the connectors to the exit sensor card and the lamp power connections at th...

Page 47: ... board to engine board J8 Check the thermistor condition and connection Check the thermistor resistance at engine board J8 3 to J8 4 It should be from 100K Ohms to 260K Ohms when cold it may be as low as 2 3K Ohms when hot but increase quickly as the fuser cools Honeycomb Areas of the page are covered by faint 6 mm circles This print defect is usually caused by the print cartridge If it is not the...

Page 48: ...ed Server problem check print server installation and configuration using the appropriate system guide to operations Light Print Light print is frequently caused by a worn out print cartridge Clean the transfer roll by powering on and off two or three times leaving the printer on for about two minutes each time Other causes are the same as for Blank Page See Blank Page on page 2 14 Make sure Print...

Page 49: ... printer If the printer completes POR successfully the printer network card and the port to the LAN are working correctly If the customer still has a problem printing see LAN Problems on page 2 21 Output Bin Sensor Examine the bin area for obstructions or damage Run the diagnos tic sensor test Make sure the plastic bails and guide are in good condition and that they guide the sensor flag out of an...

Page 50: ...move the module and inspect the tray the module D roll and the gear train Make sure the gear train is meshing with the drive gear at the bottom of the printer Look for other mechanical problems or damage Make sure the printer and module auto connectors mate properly when the module is installed Check for 34 VDC at engine board J15 2 You can test the torquer motor by shorting engine board J15 1 to ...

Page 51: ...d Removed One of the following will occur The D roll will make one complete revolution and stop with the flat side down This indicates that the mechanism is working correctly If the flat side is not facing down or if the printer had error code 20 or 28 turn the D roll if it rotates easily more than 10 either the D roll or gear 11 is damaged and should be replaced The D roll will turn continuously ...

Page 52: ...led correctly If the paper feeds but stops undamaged in the paper path run the input and exit sensor test Check for 5 VDC at the input sensor engine board J9 6 and exit sensor engine board J8 6 with paper present Check continuity on the cable before replacing a sensor If paper is curling badly enough to cause a problem feeding or stack ing see Fuser Temperature And Warm Up Time on page 3 8 Paper F...

Page 53: ...und used in the Envelope Feeder paper other than 20 or 24 pound used in the 100 sheet auxiliary feeder envelopes interleaved with paper Run the diagnostics Envelope Feed test and make sure the feed magnet is being energized If not check the resistance of the mag net at J10 1 to J10 2 on the feeder cable the resistance should be from 105 Ohms to 155 Ohms If the magnet is good reconnect the cable an...

Page 54: ...rinter print the Print Menus test page and make sure the Base code level is at least 32 00 and the Engine code level is at least 43 42 On the early machines engine board connector J5 is wired differ ently These machines require the J5 J10 external adapter box in order to support the Dual Rear Feeder On the Print Menus test page machines which require the adapter have an Engine Card of 12 or 16 mac...

Page 55: ...feeder connector There should be 88 10 ohms between pins 1 and 10 and between pins 8 and 10 Reconnect the feeder and make sure neither J5 1 nor the J5 8 test point nor the J5 10 test point has continuity to ground Skews or Jams Check for worn dirty or damaged rolls gears or envelope bucklers obstructions in the paper path correct paper envelopes properly installed edge guides and flip doors proper...

Page 56: ... through the printer before Envelopes and transparencies are not supported in the high capac ity feeder Jams Make sure the printer is installed correctly on the feeder Check for obstructions in the printer throat Make sure the paper in the tray does not have excessive curl Look between the printer and feeder to make sure the paper is entering the printer correctly Failure to feed Check the printer...

Page 57: ...r Source menu for a Tray 2 indi cation to be sure the printer detects the high capacity feeder Check feeder power supply input and output voltages If the output is cor rect pin 1 24 VDC pin 2 GND pin 3 5 VDC pin 4 GND replace the circuit board When replacing the circuit board check the A4 U S jumper to verify that the correct paper size is selected Be sure to plug each cable into the correct board...

Page 58: ...e switch varies with the paper size For Tray 1 remove the front cover disconnect the cable from the sensor and measure the resistance between the two pins on the sensor board For 500 Sheet Option or 200 Sheet Second Drawer Non Rt remove the RIP Board disconnect J15 from the engine board and measure between J15 3 and J15 4 on the cable For 200 Sheet Tray 2 Rt remove the RIP board disconnect J17 fro...

Page 59: ...inside the print cartridge It can also be caused by a failed fuser hot roll retaining toner and redepositing it on the page Check that the erase lamp voltage at engine board J9 1 is 24 VDC and that the cable has continuity To test the erase lamps jumper engine board J9 2 to ground Random Marks Random marks are nearly always due to a mechanical problem or due to foreign matter loose in the printer ...

Page 60: ...e paper in the tray is undamaged and loaded properly and the tray side restraint is properly adjusted Check the prealigner drive and auxiliary rollers springs and backup rollers for dirt wear or damage refer to the parts catalog for repair kits for broken bellcrank spring attachment hooks on the side frame Make sure all the bellcrank assemblies pivot freely Check the gear train for damage or binds...

Page 61: ...Do a developed image test to determine if the defect is occurring before or after the transfer process If you see the defect on the photoconductor check the operation of the printhead shutter and clean the printhead window with a lint free cloth folded over a cotton swab do not use a bare swab and do not use any cleaning fluids or water on the printhead window Inspect the HVPS contacts If the imag...

Page 62: ...thout a POR by selecting Reset Printer Diagnostics Mode Menu Structure The following is the Diagnostics mode menu structure The indented items are submenus available under the main menu items which are in capital letters on the operator panel Menu items referring to options will only be present if those options are installed Menus with more than four items will use MORE on the fourth operator pane...

Page 63: ...emory Tests DRAM ROM PAGE COUNTS Page Count Permanent Page Count Maintenance Count PAPER FEED TESTS Tray 1 Tray 2 Tray 3 Feeder Feeder 1 Feeder 2 Manual DUPLEX TESTS Top Margin Duplex Quick Test Duplex Feed 1 Duplex Feed 2 DEVICE TESTS Disk Test Clean Quick Disk Test Flash Test PRINTER SETUP Fuser Temperature Warm Up Time ...

Page 64: ...lean Frequency the printer will pause the number of seconds specified in Auto Clean Delay This pause minimizes the toner accu mulating on the fuser cleaner 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Auto Clean 4 Select On or Off 5 Press Return to return to the Diagnostics mode main menu Auto Clean Frequency This can be set from 10 to 255 pages with a default of 50 1 Enter Diagnostics...

Page 65: ...tton Closed is displayed until the button is released Then Open is displayed 5 Press Return to return to the Diagnostics mode main menu Charge Roll This setting varies the charge roll bias It is used to reduce back ground on the output In general if there is background and the envi ronment is hot and humid change the setting to low if the environment is cool and dry change the setting to high If t...

Page 66: ...isk by doing a multi pass write read on every block of the disk Bad blocks are flagged and removed from use If over 2000 bad blocks are found the test stops and the display indicates the disk must be replaced A message describing test progress is displayed during the test 1 Enter Diagnostics mode 2 Select DEVICE TESTS 3 Select Disk Test Clean 4 Select CONTINUE to start the test or CANCEL to return...

Page 67: ...ed in under the slot 8 Open the cover and remove the sheet of paper 9 Measure the distance from the mark on the paper to the trailing edge of the paper If the mark or hole is more than 85 mm from the trailing edge there is a paper slipping problem with the duplex unit paper feed Duplex Feed 2 Test This test verifies that paper feeds through the duplex unit properly and tests the stop point of the ...

Page 68: ...turn to the Diagnostics mode main menu Envelope Enhance Use this procedure to set the fuser solenoid power level to low medium or high Increase the level to reduce envelope wrinkling or decrease the level to reduce solenoid noise 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Envelope Enhance 4 Select Low Medium or High 5 Press Return to return to the Diagnostics mode main menu Envelope ...

Page 69: ...lash Test The operator panel will display Passed or Failed 4 Press Return to return to the Diagnostics mode main menu Fuser Temperature And Warm Up Time These settings allow adjustment of the fuser to correct problems with paper curl or melting letterheads Paper curl in which the top and bottom of the page curl away from the printed side hot paper curl can be corrected by reducing the fuser temper...

Page 70: ...Return to return to the Diagnostics mode main menu Fuser Warm Up Time 1 Enter Diagnostics mode 2 Select PRINTER SETUP 3 Select Warm Up Time 4 Select a setting of 0 through 5 Use the or key to change the number 0 is the shortest fuser warm up factory setting 5 is the longest fuser warm up 5 Press Return to return to the Diagnostics mode main menu LCD Test To test the operator panel display 1 Enter ...

Page 71: ...s 6 The display will indicate PASSED or FAILED 7 Select CANCEL to stop continuous memory test 8 Press Return to return to Diagnostics mode main menu Page Count To view or set the page count 1 Enter Diagnostics mode 2 Select PAGE COUNTS 3 Select Page Count 4 Choose any number between 0000000 and 9999999 by Select ing Next to move the cursor under each digit Select or to select the number you want i...

Page 72: ...ort It can be used to diagnose parallel port interface problems Permanent Page Count The permanent page count can be displayed only It cannot be mod ified or reset by the customer or servicer 1 Enter Diagnostics mode 2 Select PAGE COUNTS 3 Select Permanent Page Count 4 Press Return to return to the Diagnostics mode main menu Print Contrast This setting varies the developer bias to vary the print d...

Page 73: ...rgin toward the right and negative moves the margin to the left Top Margin can be set between 20 and 20 Changing the number by one moves the margin by 1 75 inch Moving the number in a positive direction moves the margin down the page and widens the top margin Moving the number in a negative direction moves the text up the page and narrows the top margin Bottom Margin can be set between 20 and 20 M...

Page 74: ...turn to the Diagnostics mode main menu Print Test 2 Print Test 2 generates two printouts a page similar to the test page and a fine dot pattern which can be used to evaluate banding or other print quality problems Print Test 2 will duplex if the duplex option is installed This test prints from the user selected default paper source if the default source is a tray or from Tray 1 if the default sour...

Page 75: ...de main menu Quick Disk Test This is a one minute test which performs a non destructive write read on one block per track on the disk It tests the printer to disk communications and the disk hardware and circuitry but does only incidental testing of the disk surface itself The Quick Disk Test does not destroy data on the disk existing data is read and stored prior to the testing of each track and ...

Page 76: ...lex front to back registration Make sure the non duplex page registration is correct before adjusting the duplex top margin 1 Enter Diagnostics mode 2 Select DUPLEX TESTS 3 Select Top Margin 4 Select or to raise or lower the back image 0 01 inches per increment 5 Press Return to return to the Diagnostics mode main menu The Duplex Quick Test is used to verify the Duplex Top Margin 1 Enter Diagnosti...

Page 77: ...he circuits used to communicate with the host computer Note The Parallel wrap test does not test all signals used for bi directional communication Contact Lexmark Technical Support for instructions on running the Parallel Confidence Test To run the Wrap Test 1 Turn the printer off 2 Disconnect the interface cable 3 Install the wrap plug in one of the interface cable connectors Note Install the par...

Page 78: ...print quality problems You might have to practice this procedure several times to get the timing correct To run the Developed Image Test 1 Open the front exit tray 2 Print the test page 3 As soon as the leading edge of the paper is visible coming out the front exit slot turn off the printer 4 Remove the print cartridge and look at the image on the photo conductor LAN Information The printer may be...

Page 79: ...connectors which are inaccessible with the RIP board in place The printer has a service mode which allows you to test the printer without the RIP board installed This verifies that the motors sensors printhead and electrophotographic process are working correctly In this mode the operator panel has minimal func tion service codes are not displayed and most error handling is dis abled during normal...

Page 80: ...atic electricity in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are e...

Page 81: ... A 2 Position the spring B so it clears the separator roller by 1 9 0 2 mm 0 075 0 008 in 3 Tighten the mounting screw Paper Restraint Spring On The 100 Sheet Auxiliary Feeder Adjustment 1 Loosen the mounting screw A 2 Position the spring B so it clears the separator roller by 1 0 0 2 mm 0 040 0 008 in 3 Tighten the mounting screw ...

Page 82: ...net Adjustment 1 Hold the armature A in the closed coil active position 2 Loosen the mounting screw B and rotate the magnet assem bly so the armature clears the clutch gear by 0 30 0 20 mm 0 012 0 008 in 3 Tighten the screw 4 Check the adjustment on both sides of the gear ...

Page 83: ...ise extra sheets may feed at random times or paper may feed continuously after the first page is fed To adjust 1 Remove the mounting screw at the front of the torquer 2 Loosen the mounting screw at the rear of the torquer 3 Pivot the torquer up to disengage it from the gear 4 Turn the torquer to its detented position 5 Position the gear so the timing mark A is centered in the win dow 6 Pivot the t...

Page 84: ...table gear in one direction to check for back lash To adjust backlash 1 Loosen the nut on the idler stud 2 Move the idler stud downward in its slot 3 Insert a 0 95 mm 037 in feeler gage between the gear shoul ders from the front of the machine You may need to use an angled or very small feeler gauge 4 With the nut snug but not tight tap the idler upward until the gage is snug between the gear shou...

Page 85: ...Repair Information 4 6 4049 XXX Fuser Gear Right Sideplate Nut Stud Idler Gear 0 95 0 15 037 006 ...

Page 86: ...olenoid must be mounted on the fuser for this adjustment and should be at room temperature 1 Loosen screw A 2 Remove the rubber washer 3 Rotate shaft B eccentric to obtain 4 2 mm 0 2 mm 0 165 in 0 008 in air gap 4 Tighten screw A 5 Replace the rubber washer ...

Page 87: ...p check for 0 60 mm 0 07 mm 0 024 in 0 003 in between the foam pad and the magnet pole piece If adjustment is required continue 3 Keep the armature latched and loosen the magnet mounting screw A 4 Insert the feeler gauge 5 Rotate the magnet against the feeler gauge 6 Tighten the mounting screw 7 The gauge should pass between the foam pad and the magnet pole piece with moderate resistance ...

Page 88: ...e spring loaded exit stacker 2 Loosen the screws A 3 Run Print Test 1 or the Quick Test on the Diagnostics Menu 4 Move the pointer B to eliminate the skew Moving the pointer toward the left raises the left adjustment point on the printout Each mark is equivalent to one dot of the skew adjustment points 5 Tighten the screws and verify the adjustment ...

Page 89: ... the rear pivot pin and lift the cover off the rear pivot pin Front Cover Removal 1 Unplug the power cord 2 Remove the paper tray 3 Open the top cover 4 Open the right cover 5 Release the latches B You can reach the lower latches through the paper tray opening 6 Lift the right side of the cover to disengage the latch D 7 Slide the cover to the right to disengage the bracket from the posts 8 Pull t...

Page 90: ...4 11 4049 XXX ...

Page 91: ...nd lift the end to release it 5 Push the top of the cover to the left 6 Remove the cover by sliding it to the rear of the machine Top Cover Removal 1 L Lx and Lx Remove stacker plate by pulling upward 2 Remove the top cover screws C 3 Lift the rear of the cover first then the front and lift the cover off 4 Rest the cover on the machine and disconnect the operator panel cable ...

Page 92: ...4 13 4049 XXX ...

Page 93: ...aper tray 3 Remove the print cartridge 4 Remove the fuser input guide 5 Remove the transfer roll housing assembly 6 Pull the D roll firmly to the left to remove it Note The D roll is designed to be installed only once if it is removed for any reason it should be replaced with a new one It may take considerable force to install the new D roll Drive Motor Removal 1 Unplug the power cord 2 Remove the...

Page 94: ...wn so you can set the count on the new engine board 2 Turn the printer off 3 Remove the RIP board and the inner EMC shield together 4 Disconnect the engine board cable connections 5 Remove the nut and the three threaded standoffs 6 Unsnap the board from the plastic standoff ...

Page 95: ... XXX Exit Sensor Board Removal 1 Remove the front cover 2 Disconnect the fuser sensor cable 3 Disconnect the thermistor cable 4 Disconnect the fuser solenoid cable 5 Release the latches A 6 Pull the sensor board down to remove it ...

Page 96: ...ft by disengaging the right end to the rear of the machine 5 Disconnect the long redrive belt A and slip it off the lower shaft 6 L Lx and Lx Disconnect the output bin sensor cable 7 Remove the redrive assembly screws D 8 Remove the plenum assembly and screws B 9 Unplug the fan cable The fan C can now be removed from the plenum assembly ...

Page 97: ...IT BEFORE YOU SERVICE THIS UNIT ALLOW THE MACHINE TO COOL FOR 5 MINUTES 1 Unplug the power cord 2 Remove the printer cartridge 3 Through the opening for the paper output flip the metal ESD shield up out of the way and disconnect the exit sensor cable from the fuser 4 Remove the fuser cover 5 Disconnect the power wires A from the left side of the fuser 6 Remove the fuser input guide 7 Completely lo...

Page 98: ...ng the rear end of the guide and unsnapping both sides from the fuser 2 Lift the fuser input guide upward at both sides near the fuser and slide the guide toward the rear of the machine to release 3 Lift the guide out of the machine 4 Clean the fuser input guide before installing it ...

Page 99: ...te The fuser lamp is a glass heater Do not touch the lamp with your hands skin oils and acids can reduce the life of the heater lamp Use a soft cloth to handle the heater lamp at all times if the lamp is to be reinserted 1 Remove the fuser 2 Remove the right lamp bracket A 3 Carefully pull the lamp B out to the right using a soft cloth if the lamp is to be reinserted Install the new lamp with the ...

Page 100: ...rn the printer off 2 Remove the RIP board and the inner EMC shield together 3 Disconnect the cable from the exit sensor board 4 Remove the front cover 5 Disconnect the cable from the paper sensor assembly 6 Remove the cable through the right frame ...

Page 101: ...d Removal 1 Remove the fuser 2 Remove the two mounting screws A holding the solenoid housing to the fuser housing 3 Disengage the solenoid bracket from the plunger Note When a new solenoid assembly is installed the fuser sole noid must be adjusted ...

Page 102: ...user cover 3 Pry the thermal fuse connectors off the terminals at each end of the fuser 4 Disconnect the thermistor cable from the fuser exit board and free the cable from the cable guides 5 Release the metal shroud from the fuser by prying up on the slotted tab at each end then rotating the shroud toward the rear 6 Remove the shroud assembly by bending the left frame of the fuser slightly to the ...

Page 103: ...ugh the hole D 11 The power supply is held in place by two latches on the left side To release the latches 12 Push one latch E in and raise one of the studs F to release the latch 13 Push the other latch E in and raise the other stud F to release the latch 14 Lift the power supply until the studs F align with the large openings then move the power supply to the right to release it from the frame 1...

Page 104: ...4 25 4049 XXX ...

Page 105: ...sor Board Removal 1 Remove the fuser input guide 2 Remove the transfer roll housing 3 Remove the D roll 4 Disconnect the input sensor cable from the input sensor board Note Use care the flag can be damaged while removing the board 5 Release latch B and pull the board down and forward to get it out of its mounting 6 Disconnect the toner sensor cable from the board 7 Remove the sensor board ...

Page 106: ...4 27 4049 XXX ...

Page 107: ...sing 5 Disconnect the cable from the HVPS 6 Remove the RIP board and the inner EMC shield together 7 Remove the engine board 8 Disengage the upper frame cables from the guide in the paper feed side frame 9 Remove the screws B 10 Remove the fuser cover 11 Unplug the fuser wires C and push them below the HVPS 12 Unplug the paper size switch cable 13 Lift the lower frame assembly straight up to separ...

Page 108: ...ers 4 Remove the RIP board and the inner EMC shield together 5 Remove the left and right LVPS mounting screws and the screw for the cable tie 6 Disconnect the LVPS cable from the engine board 7 Disconnect the fuser connector A 8 Lift the supply up and then toward the right side frame to discon nect the On Off switch linkage ...

Page 109: ...ation 4 30 4049 XXX LVPS Cover Removal 1 Form tabs D away from the power supply to create clearance for tabs A to move downward 2 Release the top latches A 3 Release the side latches B 4 Release the bottom latches C ...

Page 110: ... Feed Rollers Removal Note Replace all paper feed drive rollers at the same time 1 Remove the lower frame 2 Disconnect the cable from the input sensor 3 Remove the screws A and the outer deflector 4 Remove the screws B and the toner shield E 5 Separate the side frames 6 Pull the guides C out of the side frames 7 Use a flat blade tool to snap the gears and rollers D off the shaft ...

Page 111: ...RIP board and engine board 4 Remove the LVPS 5 Locate the paper feed magnet mounting screw B visible through the right side frame A 6 Remove the mounting screw B 7 Remove the paper feed magnet assembly from the rear slip the connector under the right frame After you replace the magnet make the Paper Feed Magnet Adjust ment on page 4 8 ...

Page 112: ...XX Paper Size Switch Removal 1 Remove the paper tray 2 Remove the front cover 3 Unplug the cable B from the switch connector C 4 Remove the two screws A 5 Rotate the switch about 90 and pull it out of the printer ...

Page 113: ...Remove the right and top covers 4 Remove the exit redrive and its belt 5 Remove the air plenum 6 Remove the screws A and the pointer 7 Cut and discard the printhead cable clamp 8 Disconnect the connectors B 9 Remove the printhead and the printhead shroud 10 Pry off the grip rings holding the printhead to the shroud Note After you replace the printhead perform the Printhead Skew Adjustment on page ...

Page 114: ...on on the new board Toner Sensor Removal 1 Remove the fuser input guide 2 Remove the transfer roll housing 3 Lift the input sensor board far enough to disconnect the cable 4 Remove the end of the bellcrank spring 5 Lift the sensor to unsnap it 6 Work the cable out of the frame and remove the sensor Torquer Motor Removal 1 Remove the lower frame assembly from the base 2 Remove the D roll 3 Remove g...

Page 115: ... cover from the front with your left hand Use a small screwdriver to push the rear latch forward and release the bearing cover This exposes the bearing on the end of the transfer roll 4 Grasp the bearing on the end of the transfer roll Lift slightly and move it to the left until the right end of the transfer roll shaft slides out of the right side bearing 5 Remove the transfer roll 6 Lift the righ...

Page 116: ... guide 3 Grasp the housing and pull toward the front of the machine to disconnect the housing from the mounting studs visible through openings B in the inner deflector 4 Lift the transfer roll housing far enough to disconnect the erase lamp cable 5 Lift the transfer roll housing out of the machine ...

Page 117: ...inner EMC shield together 5 Remove the engine board 6 Remove the load box latches A 7 Release the latches B 8 Pivot the upper frame to the rear to release the spring tension 9 Unsnap the plastic insert D holding the upper frame cables in the right side frame 10 Remove the screws C 11 Remove the upper frame cables through the side frame 12 Lift the upper frame off the machine ...

Page 118: ...Table Cover Removal 1 Open the top cover by pulling up at A and pivoting 90 2 Pry the top cover from the bottom cover at B 3 Release latches C on the table cover and lift up 4 Release latch D and lift the table cover out of the front assem bly ...

Page 119: ...ver Removal 1 Pry up on tabs A After the tabs are released lift up on the cover rotate the cover out and slide it to the right to completely remove it 2 Disconnect the exit sensor card cables 3 Press the exit sensor flag actuator B and lift out the exit sensor card ...

Page 120: ...blind connector 4 Pry up on the blind connector to remove it from the bottom cover 5 Release the two latches A on the frame assembly and lift it out of the bottom cover 6 Pry up the entry sensor card at B so it will clear the mounting stud and pull it out of the frame assembly Note When re installing the sensor lift up the flags so they will clear the sensor and not be damaged ...

Page 121: ...d lift the system board out 3 Remove the two motor mounting screws B 4 Lift the motor out of the frame assembly Note Reinstall the motor so the belt is not tight but will not jump teeth on the timing pulley Note The remaining FRU is the Gearblock Assembly When you replace this FRU see Lubrication Specifications on page 6 1 ...

Page 122: ...mbly must be installed such that there is a gap between the gear face and the plate To reinstall the plate with the torquer gears in the correct positions see Dual Rear Feeder Gear Alignment Adjustment on page 4 4 Dual Rear Feeder Right Cover There are five snaps holding the right cover to the frame 1 Free the cable from the cover by pulling the grommet down ward 2 Pull the lower front of the cove...

Page 123: ... 4 Remove the RIP board and inner EMC shield together 5 Remove the cable cover near the right cover pivot pin 6 Disconnect J15 and J17 from the engine board and push the cables down through the hole into the base 7 Carefully turn the machine onto its left side 8 Remove the four screws holding the second drawer to the printer avoiding damage to the two cables and remove the drawer ...

Page 124: ...outlet 3 Remove all paper trays and auxiliary rear feeders from the printer 4 Remove the printer from the feeder 5 Remove the two roller retainers from the feedroll shaft 6 Slide the roller shaft to one side to disengage it then lift and slide the other way to free both ends from the arms 7 Lift the shaft keeping the drive chain engaged 8 Slide the rollers off each end ...

Page 125: ...has words on the metal bearing on the flange side the left roller does not 9 Install the new feed rollers with the flanges facing inward toward the drive chain 10 Reinstall the roller shaft making sure the drive chain is still engaged 11 Reinstall the roller retainers 12 Reinstall the printer reconnect power and test ...

Page 126: ...s from the printer 4 Remove the printer from the feeder 5 Remove the four screws in the top of the feeder 6 Carefully place the feeder on its left side and remove the eight screws holding the cover to the bottom plate The feeder mech anism is attached to the bottom plate 7 Slide the feeder and bottom plate partially out of the cover Dis connect the power supply cable and the door switch cable from...

Page 127: ...ssemblies gears connectors and ground straps Major Assembly Locations Operator Panel Fan Upper Frame Print Cartridge Low Voltage Transfer Roll Power Supply RIP board Toner Sensor Inout Sensor Paper Feed Output Sensor Lower Frame Paper Tray Fuser High Voltage Power Supply Print Head Exit Redrive Engine Board ...

Page 128: ...5 2 4049 XXX Gear Train ...

Page 129: ...Connector Locations 5 3 4049 XXX HVPS Transfer Roller Housing Cover Interlock Print Cartridge Contacts Transfer Roll Contacts Transfer Roll Erase Lamp Window ...

Page 130: ...5 4 4049 XXX Engine Board Connectors J17 J16 J15 J14 J13 J12 J11 J10 J10 J9 J8 J7 J6 J5 J4 J1 J2 J3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 J16 J17 ...

Page 131: ...rive Motor J7 Board to Board Connector J8 Exit Paper Size Sensor Fuser Solenoid J9 Input Toner Sensor Board Erase Lamps J10 Envelope Feeder Magnet J11 Printhead Hsync J12 Printhead Laser J13 HVPS J14 Torquer Motor or Paperfeed Magnet Tray 1 J15 500 Sheet Option or 200 Sheet Second Drawer Non Rt J16 Jumper Tray 2 Rt J17 Torquer Motor Paper Size Sensor Tray2 Rt J18 Reserved JF1 Reserved ...

Page 132: ...nector Name J1 Font Card on back of board J2 J3 Parallel Port J4 Board to Board J5 J6 INA Disk 1 J7 ROMM SIMM flash memory option J8 ROMM SIMM printer microcode J9 DRAM SIMM J10 DRAM SIMM J11 Serial Port J12 INA Disk 2 J9 J10 J12 J6 J3 J4 J7 J8 J11 ...

Page 133: ... 2 J2 3 3 J2 4 4 J2 5 5 J2 6 6 J2 7 2 J2 8 1 Short Plastic Standoff Engine Board Male Female Standoff with Groove Female Female Standoff with Groove 5X Nut with Captive Star Washer 4X Nut with Captive Star Washer Tall Plastic Standoff RIP Board Medium Plastic Standoff Male Female Standoff without Groove Female Female Standoff without Groove ...

Page 134: ...5 8 4049 XXX Operator Panel Output Bin Sensor Cable Op Panel Cable Connector Pin 1 Pin 1 ...

Page 135: ...able is sometimes used on the Optra R R and Rx but the output bin sensor leads are not used Operator Panel Output Bin Sensor Cable Connectors Pin Op Panel Sensor L Lx Lx J1 1 1 J1 2 2 J1 3 3 J1 4 4 J1 5 5 J1 6 1 J1 7 2 J1 8 3 J1 9 No connection ...

Page 136: ...e Duplex Autoconnect Cable Connectors Engine Board Autoconnect J3 1 No connection J3 2 1 right most pin J3 3 2 J3 4 3 J3 5 4 J3 6 5 J3 7 6 Pin 1 H sync Connector Print Head Cable Fan Connector Pin 1 Laser Connector Pin 1 Pin 1 Mirror Motor Connector Mirror Motor Cable ...

Page 137: ...inter Ground Straps Outer Deflector to Lower Frame HVPS to Frame Operator Panel to Upper Frame Toner Shield to Lower Frame Load Box Shaft to Upper Frame Static Brush to Lower Frame Toner Shield to Lower Frame Load Box Shaft to Upper Frame ...

Page 138: ...Connectors High Capacity Feeder Board Connectors Connector Name J2 Elevator Motor J3 Paper Feed Motor J4 Lower Limit Switch J5 Door Switch J6 Paper Out Switch J7 R L Selector Switch J8 Upper Limit Switch J9 Power Supply J10 Feeder Ready Switch ...

Page 139: ...ssing or altered parts especially in the area of the On Off switch and the power supply Damaged missing or altered covers especially in the area of the top cover and the power supply cover Possible safety exposure from any non Lexmark attachments Lubrication Specifications Lubricate only when parts are replaced or as needed not on a scheduled basis Use of lubricants other than those specified can ...

Page 140: ...dler and its stud on the rail The prealigner drive roller and its stud on the rail The prealigner backup roller and its shaft and thrust washer The fixed center idler gear in the 500 sheet base and its shaft The idler gear in the 500 sheet base and its shaft Use IBM no 23 grease Approved equivalent Shell Darina 1 to lubri cate Front pivot latch studs Gear no 8 teeth at gear no 7 contact points Gea...

Page 141: ...80 Scheduled Maintenance at each 200K page count interval It is nec essary to replace the fuser assembly transfer roller D roll and lower redrive shaft assembly at this interval to maintain the print quality and reliability of the printer These items are available as individual FRUs They are also available as a maintenance kit through the dealer options ordering channel After replacing the kit the...

Page 142: ...ve the print cartridge 2 Fold a lint free cloth over a cotton swab 3 Open the shutter 4 Insert the swab and cloth combination in the printhead window slot then slide it left to right several times Move the swab to a clean spot on the cloth and repeat the cleaning procedure Do this procedure several times to make sure the window is clean Cleaning The Transfer Roller Power off the printer Power on a...

Page 143: ...t AR As Required in the Units column indicates that the quan tity is not the same for all machines NS Not Shown in the Asm Index column indicates that the part is procurable but is not pictured in the illustration INDENTURE The indenture is marked by a series of dots located before the parts description The indenture indicates the relationship of a part to the next higher assembly For example INDE...

Page 144: ...7 2 4049 XXX Assembly 1 Covers ...

Page 145: ...8176 1 Right Cover Asm 4 1381865 1 Plastic Latch Right Cover 4 1381862 1 Metal Latch Right Cover NS 1408233 1 Spring Right Cover Latch 5 1408184 1 Front Cover Asm R Rx Rt plastic latch 5 1408384 1 Front Cover Asm L Lx plastic latch 5 69G9481 1 Front Cover Asm R Rx Rt metal latch 5 69G9482 1 Front Cover Asm L Lx metal latch 5A 1381858 1 Bracket Front Cover Retaining plastic latch 5A 1381864 1 Brack...

Page 146: ...7 4 4049 XXX Assembly 2 Lower Frame ...

Page 147: ...s Packet 1381663 6 1328243 1 Gear No 2 7 1039391 2 Detent Box 8 1329013 1 Right Cartridge Latch 9 1 Spring Parts Packet 1381666 11 1039271 1 Shaft Gear 2 12 1 Nut Gear 2 Parts Packet 1381663 13 1 Lockwasher Gear 2 Parts Packet 1381663 14 1329144 1 Left Cartridge Latch 15 1408645 1 Gear Train Cover 18 1328428 1 LH Bracket Duplex 19 1328427 1 RH Bracket Duplex NS 1 Screw Duplex Bracket Parts Packet ...

Page 148: ...7 6 4049 XXX Assembly 3 Upper Frame ...

Page 149: ...s Packet 1381663 7 1 Spring Bellcrank Parts Packet 1381666 8 1039692 1 Left Bellcrank 9 1383998 1 Fan Asm NS 1424481 1 Pad Acoustic Fan 10 1328222 1 Plenum Asm 11 1 Retainer Parts Packet 1381663 12 1 Spring Parts Packet 1381666 16 2 Screw Plenum Mtg Parts Packet 1381663 18 1408616 1 Handle Latch with Grip R Rx Rt 18 1408216 1 Handle Latch with Grip L Lx 19 1328308 2 Sleeve 20 1 Spring Handle Parts...

Page 150: ...7 8 4049 XXX Assembly 4 Printhead ...

Page 151: ...408034 1 Cable hsync NS 1038199 1 Cable Tie 5 1425284 1 Cable Laser Install with marked end to Printhead 6 1 Pin Parts Packet 1381666 7 1 Spring Parts Packet 1381666 8 2 Screw Printhead Mtg Parts Packet 1381663 8A 1 Screw Hex Headed Parts Packet 1381663 8B 1 Pointer Parts Packet 1381663 8C 1 Clip Hex Screw Ground Parts Packet 1381663 9 2 Retainer Parts Packet 1381663 ...

Page 152: ...7 10 4049 XXX Assembly 5 Paper Feed ...

Page 153: ... 1 Left Frame 11 1039175 1 Tray Frame Spring 12 1042211 1 Belt Redrive R Rx Rt 12 1328192 1 Belt Redrive L Lx 13 1328193 1 Belt Auxiliary L Lx 14 1381912 1 Shaft Asm Lower Redrive 15 1408249 1 Extension Asm Right Rail 16 1381908 1 Shaft Asm Upper Redrive 17 1381914 1 Shaft Asm Auxiliary Shaft L Lx 18 1381910 1 Shaft Asm Middle Redrive R Rx Rt 18 1328173 1 Shaft Asm Middle Redrive L Lx 19 1381073 1...

Page 154: ...7 12 4049 XXX Assembly 5 Paper Feed Continued ...

Page 155: ...rew Redrive Mtg Parts Packet 1381663 33 1038186 1 Guide Fuser Input 34 1381895 1 Redrive Assembly L Lx 34 1381899 1 Redrive Assembly R Rx Rt 35 6 Screw Frame to Paper Feed Parts Packet 1381663 NS 1328345 1 Spring Bias Transfer Housing 36 1381298 1 Output Bin Sensor L Lx 37 1408064 1 Cable Output Bin Op Panel Output Bin lead has no connection on R Rx Rt 38 1381567 1 Guide Bail and Minibail Kit R Rx...

Page 156: ...7 14 4049 XXX Assembly 6 Paper Feed Alignment Gears ...

Page 157: ...1 o Thrust Washer 2 1381145 1 Kit Prealigner and Auxiliary Rollers 3 1039278 1 Gear Idler Prealigner 4 1 Spring Prealigner and Metering Bellcranks Parts Packet 1381666 5 1328384 1 Bellcrank Prealigner 1 o Shaft 1 o Roll 1 o Bellcrank 1 o Thrust washer N S 1383580 1 Anchor Repair Kit Metering N S 1383908 1 Anchor Repair Kit Prealigner ...

Page 158: ...7 16 4049 XXX Assembly 7 Paper Feed Drive ...

Page 159: ...81801 1 Rail Asm Right with Gears and Paper Pick Solenoid 5 1328313 1 Shield D Roll 6 1328454 1 Shaft D Roll with Gear 11 Solenoid 6 1381726 1 Shaft D Roll with Gear 11 Torquer Motor 8 1381886 1 Gear Kit 9 1381306 1 Torquer Motor 10 1408243 1 Adapter Torquer Motor 11 1 Screw Parts Packet 1381663 12 1 Spring Gear Advance Parts Packet 1383316 13 1383433 1 Solenoid Paper Pick 14 1 Spring Magnet Arm P...

Page 160: ...7 18 4049 XXX Assembly 8 Standard Paper Tray 200 Sheet ...

Page 161: ...ssembly for Labels 11 in 200 sheet 1364890 1 Paper Tray Assembly for Labels 14 in 200 sheet 1364891 1 Paper Tray Assembly A5 1 1408170 1 Cover 14 in 2 1408725 1 Paper Stop 3 1381577 1 Corner Buckler 4 1408732 1 Liner 11 in 4 1408733 1 Liner 14 in 5 1408724 1 Adjustable Guide 6 1058486 1 Universal Paper Tray 6A 1058488 1 Guide Universal Paper Tray 7 1381661 1 Kit Paper Level Indicator ...

Page 162: ...7 20 4049 XXX Assembly 9 Paper Tray 500 Sheet ...

Page 163: ...14 in 1381809 1 Paper Tray Assembly Super Heavy Weight Labels 750g spring 11 in 1 1408361 1 Bottom Cover 11 in 1 1408362 1 Bottom Cover 14 in 2 1381660 1 Cover Front Trim 11 in 2 1408369 1 Cover Front Trim 14 in 3 1408708 1 Paper Guide 4 1408387 1 Slide 11 in 4 1408388 1 Slide 14 in 5 69G9056 1 Paper Stop 5A 1408710 1 Slider Paper Stop 6 1408170 1 Cover 14 in 7 1195835 1 Pivot Plate with label 8 2...

Page 164: ...7 22 4049 XXX Assembly 10 Base for Paper Drawer 500 Sheet ...

Page 165: ...s Catalog 7 23 4049 XXX Asm Index Part Number Units Description 10 1 1408289 1 Housing 2 1039558 1 Roll 3 1409146 1 Plate Assembly Gear 4 1039170 4 Pad Machine NS 1328674 1 Clip Ground NS 4 Screw PP 1381663 ...

Page 166: ...7 24 4049 XXX Assembly 11 Second Paper Drawer 200 Sheet ...

Page 167: ...tch Asm 5 1381839 1 Tray Guide Right 6 1381841 1 Tray Guide Left 7 1381831 1 Drive Asm NS 1381918 1 o Drive Asm Gear Kit 8 1381842 1 D Roller Tire 9 1381843 1 Drive Roller 10 1381306 1 Torquer Motor 11 1381844 1 Bellcrank Asm 12 1381845 1 Deflector 13 1381846 1 Ground Clip 14 1381847 1 Cable Engine Board Rt 14 1408062 1 Cable Non Rt NS 1381861 1 Mounting Plate Connector Non Rt NS 1 Screw Parts Pac...

Page 168: ...7 26 4049 XXX Assembly 12 Optional Paper Drawer 500 Sheet ...

Page 169: ... Bellcrank Assembly NS 1 Spring Bellcrank Parts Packet 1381666 6 1039603 1 Drive Roller 7 1039540 1 D Roller Tire 8 1381306 1 Torquer Motor 11 1 Spring Parts Packet 1381666 12 1381638 1 Drive Assembly NS 1381920 1 o Drive Asm Gear Kit 14 1039558 1 Roller 15 1183299 1 Switch Assembly 16 1 Screws Parts Packet 1381663 17 1381887 1 Cable Paper Drawer ...

Page 170: ...7 28 4049 XXX Assembly 13 Fuser ...

Page 171: ... Parts Packet 1381663 8 1381523 1 Fuser Lamp 110 V R L Rt Install lamp with color coded end away from gear 8 1381524 1 Fuser Lamp 220 V R L Rt Install lamp with color coded end away from gear 8 1381011 1 Fuser Lamp 110 V Rx Lx R Rt Lx Install lamp with color coded end away from gear 8 1381037 1 Fuser Lamp 220 V Rx Lx R Rt Lx Install lamp with color coded end away from gear 8A 1381146 1 Hot Roll As...

Page 172: ...7 30 4049 XXX Assembly 13 Fuser Continued ...

Page 173: ...81665 21 1 Spring Redrive Idler Parts Packet 1381666 22 1328437 1 Contact Asm Right Lamp 23 1328438 1 Contact Asm Left Lamp 24 2 Screw Mtg Parts Packet 1381663 25 1039316 5 Detack Fingers 26 1039317 5 Detack Finger Springs 27 1427473 1 Detack Housing W Fingers and Springs 28 1375937 1 Lower Exit Guide 29 1381786 1 Shroud W Thermal Fuse Thermistor and Clips R L Rt 29 1381788 1 Shroud W Thermal Fuse...

Page 174: ...7 32 4049 XXX Assembly 14 Electronics ...

Page 175: ...Cord Set S Africa 3 1342533 1 Power Cord Set Switzerland 3 1342534 1 Power Cord Set Chile Italy 3 1342535 1 Power Cord Set Denmark 3 1342536 1 Power Cord Set New Zealand Australia Argentina Paraguay 3 1342537 1 Power Cord Set Israel 3 1342543 1 Power Cord Set UK Malaysia Singapore 4 1408274 1 Rod on off 4A 1408277 1 Support Rod on off 4B 1408198 1 Actuator On Off 4C 1408275 1 Plate On Off Actuator...

Page 176: ...7 34 4049 XXX Assembly 14 Electronics Continued ...

Page 177: ...SIMM 2MB R Rt 9 1364876 1 DRAM SIMM 8MB Lxi 11 1381651 1 Inner EMC Shield R Rt L Lx Rx 11 1381848 1 Inner EMC Shield R Rt Lx NS 1381664 1 Standoff Kit Board Mounting 13 1408106 1 Guide Font Card NS 2 Screw HVPS Mtg Parts Packet 1381663 18 2 Screw LVPS Mtg Parts Packet 1381663 19 1383513 1 Switch On Off 20 1039456 1 Switch Pivot 21 1381840 1 ROM SIMM R Rt L Lx Rx 21 1381872 1 ROM SIMM Lx R Rt ...

Page 178: ...7 36 4049 XXX Assembly 15 Transfer Roll ...

Page 179: ...iption 15 1381922 1 Transfer Roll Asm complete 15 1 1381008 1 Roll Asm Transfer With Right Bearing 2 1381652 1 Housing Transfer 1 o Rear Lens Asm Erase 1 o Contact Transfer Roll 1 o Lamp Asm Erase 3 1328356 1 Cover Clip Bearing NS 1381923 1 Erase Lamp Asm w lens ...

Page 180: ...7 38 4049 XXX Assembly 16 Duplex Option 1 3 4 5 6 7 8 9 10 12 13 14 2 15 19 23 20 22 16 18 17 21 24 25 ...

Page 181: ... 1 Cable Sensor and Autoconnect 14 1381025 1 Paper Feed Motor DC 15 1326113 1 Switch Asm Cover Open 16 1381570 1 Switch Asm Front Exit 17 1408969 1 Cover Corner Trim 18 1408942 1 Cover Auto connect Plug 19 1326064 1 Belt Paper Drive 20 1381803 1 Tray Asm 300 w Top Cover L Lx 20 1364882 1 Tray Asm 130 w Top Cover R Rx Rt 21 1408888 1 Paper Stop 300 Tray 21 1408880 1 Paper Stop 130 Tray 22 1381560 1...

Page 182: ...7 40 4049 XXX Assembly 17 Envelope and 100 Sheet Auxiliary Feeder ...

Page 183: ...2529 1 Screw 3 1039615 1 Spring 4 1383944 1 Magnet Assembly 5 1622303 1 Washer 6 1622536 1 Screw Mtg 7 1408869 1 Cover Right 8 1408868 1 Guide Large 8A 1408861 1 Latch Guide 9 1408863 1 Guide Small 10 1183273 1 Spring Override Lever 100 Sheet Auxil iary Feeder Only NS 1383934 1 Roller Pack Envelope Feeder Only NS 1383935 1 Roller Pack 100 Sheet Auxiliary Feeder Only ...

Page 184: ...7 42 4049 XXX Assembly 18 Dual Rear Feeder ...

Page 185: ...ual Torquer Asm 3 4 Screw Torquer PP 1367169 4 1381793 1 Gear Kit 5 1381794 1 Roller Kit 6 1367019 1 Envelope Buckler Kit 7 1367463 2 Pick Roll Hub Kit 8 1381833 2 Extender 9 1381795 2 Edge Guides Width Adjust Strip Kit 10 1381834 1 Slider 11 1381797 1 Door 12 3 Screw Frame PP 1367169 13 1381835 2 Paper Load Shaft 14 4 Clip PP 1367169 ...

Page 186: ...7 44 4049 XXX Assembly 19 High Capacity Feeder ...

Page 187: ...7 1381934 1 Door Switch Cable Assembly 8 1381942 1 Feeder Subassembly U S 8 1381943 1 Feeder Subassembly A4 9 1381941 1 Paper feed roller kit with retainers 10 1381933 1 Circuit Board check A4 U S jumper position 11 1381935 1 Elevator Motor with pinion 12 1381936 1 Paper feed motor with pinion 13 1381937 1 Microswitch upper limit with cable 14 1381938 1 Microswitch lower limit with cable 15 138193...

Page 188: ...3 1 Option Cards 1381050 1 o INA LocalTalk 1446702 1 o INA Ethernet 10BASE2 1402217 1 o INA Token Ring 1402218 1 o INA Ethernet 10BASE T 1446702 1 o INA Ethernet Combined 10BASE2 10BASE T 13A0294 1 o INA SCS 13A0295 1 o INA IPDS 13A0296 1 o 9 pin to Twinax cable SCS or IPDS 13A0297 1 o 9 pin to BNC cable SCS or IPDS 13A0298 1 o 9 pin to 9 pin set up cable 1328563 1 o Thumbscrew INA 11 1364915 1 Fo...

Page 189: ... 7 14 parts packet 1381145 1 Metering and Prealigner rolls parts packet 1329301 1 Grease 2g 1384076 1 Grease conductive 1 oz 1383586 1 Grease damping 1 oz 9900692 1 Grease IBM 23 1280443 1 Oil IBM 10 4 oz 1381561 1 Duplex Gears parts packet 1381048 1 Duplex Flags parts packet 1381669 1 Jumpers Flags parts packet 1381664 1 Standoffs parts packet 1381661 1 Indicator parts packet 200 sheet tray 13833...

Page 190: ...2 Envelope Feeder magnet 4 3 fuser drive gear backlash 4 5 fuser solenoid 4 7 paper restraint spring 4 2 printhead skew 4 9 auto clean 3 3 auto clean delay 3 4 auto clean frequency 3 3 B background 2 12 banding 2 12 black page 2 13 blank page 2 14 blurred or fuzzy print 2 15 button test 3 4 C charge roll 3 4 connector locations 5 1 connectors duplex option autoconnect cable 5 10 engine board 5 4 g...

Page 191: ...connectors 5 10 bottom cover removal 4 41 entry sensor card removal 4 41 exit card and cover removal 4 40 parts assembly 7 38 system card and motor removal 4 42 top cover and table cover removal 4 39 duplex quick test 3 15 E electronics parts assembly 7 32 7 34 engine board connectors 5 4 removal 4 15 envelope enhance 3 7 envelope print test 3 7 Envelope Feeder envelope restraint spring adjustment...

Page 192: ...eed rollers removal 4 45 honeycomb 2 20 horizontal void or streak 2 20 HVPS connectors 5 3 removal 4 24 I INA removal 4 26 inner EMC shield removal 4 35 input sensor board removal 4 26 L LAN information 3 17 problems 2 21 LCD test 3 9 light print 2 21 lubrication specifications 6 1 LVPS cover removal 4 30 removal 4 29 M maintenance approach 1 3 maintenance kit count 3 10 marks random 2 32 regularl...

Page 193: ...der 2 26 2 27 high capacity feeder 2 29 paper feed tests 3 10 paper size sensing problem 2 31 paper size switch removal 4 33 parts catalog how to use 7 1 permanent page count 3 11 power consumption 1 2 power on self test POST 2 10 preventive maintenance 6 1 print contrast 3 11 print registration 3 12 bottom margin 3 12 left margin 3 12 top margin 3 12 print test 1 3 13 print test 2 3 13 print test...

Page 194: ...33 stalled printer 2 34 streaks 2 34 symptom table 2 11 T toner sensor removal 4 35 tools used 1 3 top margin and duplex quick test 3 15 top margin test 3 15 torquer motor removal 4 35 transfer roller cleaning 6 4 parts assembly 7 36 removal 4 36 transfer roller housing connectors 5 3 removal 4 37 transfer test 3 16 V vertical void 2 34 W wrap tests 3 16 ...

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Lexmark Optra 4049 Series, Service Manual

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Summary of Contents for Optra 4049 Series

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